Ranger 250

IM741-A

April, 2003

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SAFETY

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Diesel engine exhaust and some of its constituents are known to the State of California to cause can- cer, birth defects, and other reproductive harm.

The Above For Diesel Engines

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

The Above For Gasoline Engines

FOR ENGINE powered equipment.

1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running.

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1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes

outdoors.

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1.c. Do not add the fuel near an open flame welding arc or when the engine is running.

Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporiz- ing on contact with hot engine parts and igniting. Do not spill fuel when filling tank. If fuel is spilled, wipe it up and do not start engine until fumes have been eliminated.

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1.d. Keep all equipment safety guards, covers and devices in position and in good repair.Keep hands, hair, clothing and tools away from V-belts, gears, fans and all other moving parts when starting, operating or repairing equipment.

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1.e. In some cases it may be necessary to remove safety guards to perform required maintenance. Remove guards only when necessary and replace them when the maintenance requiring their removal is complete. Always use the greatest care when working near moving parts.

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1.f. Do not put your hands near the engine fan.

Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running.

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1.g. To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work, disconnect the spark plug wires, distributor cap or magneto wire as appropriate.

1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot.

ELECTRIC AND

MAGNETIC FIELDS may be dangerous

2.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines

2.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physician before welding.

2.c. Exposure to EMF fields in welding may have other health effects which are now not known.

2.d. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:

2.d.1. Route the electrode and work cables together - Secure them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode and work cables. If the electrode cable is on your right side, the work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close as possible to the area being welded.

2.d.5. Do not work next to welding power source.

Mar ???95

ELECTRIC SHOCK can kill.

3.a. The electrode and work (or ground) circuits are electrically ???hot??? when the welder is on. Do not touch these ???hot??? parts with your bare skin or wet clothing. Wear dry, hole-free

gloves to insulate hands.

3.b. Insulate yourself from work and ground using dry insulation. Make certain the insulation is large enough to cover your full area of physical contact with work and ground.

In addition to the normal safety precautions, if welding must be performed under electrically hazardous conditions (in damp locations or while wearing wet clothing; on metal structures such as floors, gratings or scaffolds; when in cramped positions such as sitting, kneeling or lying, if there is a high risk of unavoidable or accidental contact with the workpiece or ground) use the following equipment:

???Semiautomatic DC Constant Voltage (Wire) Welder.

???DC Manual (Stick) Welder.

???AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head, nozzle or semiautomatic welding gun are also electrically ???hot???.

3.d. Always be sure the work cable makes a good electrical connection with the metal being welded. The connection should be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical (earth) ground.

3.f. Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe operating condition. Replace damaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically ???hot??? parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders.

3.i. When working above floor level, use a safety belt to protect yourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

ARC RAYS can burn.

4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistant material to protect your skin and that of your helpers from the arc rays.

4.c. Protect other nearby personnel with suitable, non-flammable screening and/or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal.

FUMES AND GASES can be dangerous.

5.a. Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases.When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. When

welding with electrodes which require special ventilation such as stainless or hard facing (see instructions on container or MSDS) or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes, keep exposure as low as possible and below Threshold Limit Values (TLV) using local exhaust or mechanical ventilation. In confined spaces or in some circumstances, outdoors, a respirator may be required. Additional precautions are also required when welding on galvanized steel.

5.b. Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing, cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors to form phosgene, a highly toxic gas, and other irritating prod- ucts.

5.c. Shielding gases used for arc welding can displace air and cause injury or death. Always use enough ventilation, especially in confined areas, to insure breathing air is safe.

5.d. Read and understand the manufacturer???s instructions for this equipment and the consumables to be used, including the material safety data sheet (MSDS) and follow your employer???s safety practices. MSDS forms are available from your welding distributor or from the manufacturer.

5.e. Also see item 1.b.

Mar ???95

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SAFETY

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WELDING SPARKS can cause fire or explosion.

6.a. Remove fire hazards from the welding area.

If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot

materials from welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site, special precautions should be used to prevent hazardous situations. Refer to ???Safety in Welding and Cutting??? (ANSI

Standard Z49.1) and the operating information for the equipment being used.

6.c. When not welding, make certain no part of the electrode circuit is touching the work or ground. Accidental contact can cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside. They can cause an explosion even though they have been ???cleaned???. For information, purchase ???Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous

Substances???, AWS F4.1 from the American Welding Society

(see address above).

6.e. Vent hollow castings or containers before heating, cutting or welding. They may explode.

6.f. Sparks and spatter are thrown from the welding arc. Wear oil free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes and a cap over your hair. Wear ear plugs when welding out of position or in confined places.

Always wear safety glasses with side shields when in a welding area.

6.g. Connect the work cable to the work as close to the welding area as practical. Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains, crane cables or other alternate cir- cuits. This can create fire hazards or overheat lifting chains or cables until they fail.

6.h. Also see item 1.c.

CYLINDER may explode if damaged.

7.a. Use only compressed gas cylinders

containing the correct shielding gas for the process used and properly operating regulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable for the application and maintained in good condition.

7.b. Always keep cylinders in an upright position securely chained to an undercarriage or fixed support.

7.c. Cylinders should be located:

???Away from areas where they may be struck or subjected to physical damage.

???A safe distance from arc welding or cutting operations and any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any other electrically ???hot??? parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use.

7.g. Read and follow the instructions on compressed gas cylinders, associated equipment, and CGA publication P-l, ???Precautions for Safe Handling of Compressed Gases in

Cylinders,??? available from the Compressed Gas Association 1235 Jefferson Davis Highway, Arlington, VA 22202.

FOR ELECTRICALLY powered equipment.

8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment.

8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer???s recommendations.

8.c. Ground the equipment in accordance with the U.S. National Electrical Code and the manufacturer???s recommendations.

Mar ???95

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SAFETY

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PR??CAUTIONS DE S??RET??

Pour votre propre protection lire et observer toutes les instructions et les pr??cautions de s??ret?? specifiques qui parraissent dans ce manuel aussi bien que les pr??cautions de s??ret?? g??n??rales suiv- antes:

S??ret?? Pour Soudage A L???Arc

1.Protegez-vous contre la secousse ??lectrique:

a.Les circuits ?? l?????lectrode et ?? la pi??ce sont sous tension quand la machine ?? souder est en marche. Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v??tements mouill??s. Porter des gants secs et sans trous pour isoler les mains.

b.Faire tr??s attention de bien s???isoler de la masse quand on soude dans des endroits humides, ou sur un plancher metallique ou des grilles metalliques, principalement dans les positions assis ou couch?? pour lesquelles une grande partie du corps peut ??tre en contact avec la masse.

c.Maintenir le porte-??lectrode, la pince de masse, le c??ble de soudage et la machine ?? souder en bon et s??r ??tat defonctionnement.

d.Ne jamais plonger le porte-??lectrode dans l???eau pour le refroidir.

e.Ne jamais toucher simultan??ment les parties sous tension des porte-??lectrodes connect??s ?? deux machines ?? souder parce que la tension entre les deux pinces peut ??tre le total de la tension ?? vide des deux machines.

f.Si on utilise la machine ?? souder comme une source de courant pour soudage semi-automatique, ces precautions pour le porte-??lectrode s???applicuent aussi au pistolet de soudage.

2.Dans le cas de travail au dessus du niveau du sol, se prot??ger contre les chutes dans le cas ou on recoit un choc. Ne jamais enrouler le c??ble-??lectrode autour de n???importe quelle partie du corps.

3.Un coup d???arc peut ??tre plus s??v??re qu???un coup de soliel, donc:

a.Utiliser un bon masque avec un verre filtrant appropri?? ainsi qu???un verre blanc afin de se prot??ger les yeux du ray-

onnement de l???arc et des projections quand on soude ou quand on regarde l???arc.

b.Porter des v??tements convenables afin de prot??ger la peau de soudeur et des aides contre le rayonnement de l???arc.

c.Prot??ger l???autre personnel travaillant ?? proximit?? au soudage ?? l???aide d?????crans appropri??s et non-inflammables.

4.Des gouttes de laitier en fusion sont ??mises de l???arc de soudage. Se prot??ger avec des v??tements de protection libres de l???huile, tels que les gants en cuir, chemise ??paisse, pan- talons sans revers, et chaussures montantes.

5.Toujours porter des lunettes de s??curit?? dans la zone de soudage. Utiliser des lunettes avec ??crans lateraux dans les

zones o?? l???on pique le laitier.

6.Eloigner les mat??riaux inflammables ou les recouvrir afin de pr??venir tout risque d???incendie d?? aux ??tincelles.

7.Quand on ne soude pas, poser la pince ?? une endroit isol?? de la masse. Un court-circuit accidental peut provoquer un ??chauffement et un risque d???incendie.

8.S???assurer que la masse est connect??e le plus pr??s possible de la zone de travail qu???il est pratique de le faire. Si on place la masse sur la charpente de la construction ou d???autres endroits ??loign??s de la zone de travail, on augmente le risque de voir passer le courant de soudage par les chaines de lev- age, c??bles de grue, ou autres circuits. Cela peut provoquer des risques d???incendie ou d???echauffement des chaines et des c??bles jusqu????? ce qu???ils se rompent.

9.Assurer une ventilation suffisante dans la zone de soudage.

Ceci est particuli??rement important pour le soudage de t??les galvanis??es plomb??es, ou cadmi??es ou tout autre m??tal qui produit des fume??s toxiques.

10.Ne pas souder en pr??sence de vapeurs de chlore provenant d???op??rations de d??graissage, nettoyage ou pistolage. La chaleur ou les rayons de l???arc peuvent r??agir avec les vapeurs du solvant pour produire du phosg??ne (gas fortement toxique) ou autres produits irritants.

11.Pour obtenir de plus amples renseignements sur la s??ret??, voir le code ???Code for safety in welding and cutting??? CSA Standard W 117.2-1974.

PR??CAUTIONS DE S??RET?? POUR

LES MACHINES ?? SOUDER ??

TRANSFORMATEUR ET ??

REDRESSEUR

1.Relier ?? la terre le chassis du poste conformement au code de l?????lectricit?? et aux recommendations du fabricant. Le dispositif de montage ou la piece ?? souder doit ??tre branch?? ?? une bonne mise ?? la terre.

2.Autant que possible, I???installation et l???entretien du poste seront effectu??s par un ??lectricien qualifi??.

3.Avant de faires des travaux ?? l???interieur de poste, la debranch- er ?? l???interrupteur ?? la boite de fusibles.

4.Garder tous les couvercles et dispositifs de s??ret?? ?? leur place.

Mar. ???93

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Thank You

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for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product

????????? as much pride as we have in bringing this product to you!

SAFETY PRECAUTIONS

WARNING

Do not attempt to use this equipment until you have thoroughly read the engine manufacturer???s manual supplied with your welder. It includes important safety precautions, detailed engine starting, operating and maintenance instructions, and parts lists.

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ELECTRIC SHOCK can kill.

???Do not touch electrically live parts or electrode with skin or wet clothing.

???Insulate yourself from work and ground

???Always wear dry insulating gloves.

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ENGINE EXHAUST can kill.

???Use in open, well ventilated areas or

vent exhaust outside.

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MOVING PARTS can injure.

???Do not operate with doors open or guards off.

??? Stop engine before servicing.

??? Keep away from moving parts.

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LIFTING

The RANGER 250 weighs approximately 575 lbs. with a full tank of gasoline. A lift bail is mounted to the machine and should always be used when lifting the machine.

ADDITIONAL SAFETY PRECAUTIONS

WARNING

FALLING EQUIPMENT can cause injury.

??? Do not lift this machine using lift bale if it is equipped with a heavy accessory such as trailer or gas cylinder.

???Lift only with equipment of ade- quate lifting capacity.

???Be sure machine is stable when lifting.

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HIGH ALTITUDE OPERATION

At higher altitudes, output de-rating may be neces- sary. For maximum rating, de-rate the welder output 3.5% for every 1000 ft. (305m). Contact an autho- rized engine service shop for modifications to operate above 5,000 ft. (1525m).

??? See additional warning information at front of this operator???s manual.

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???Only qualified personnel should install, use, or service this equipment.

LOCATION AND VENTILATION

The welder should be located to provide an unrestrict- ed flow of clean, cool air to the cooling air inlets and to avoid restricting the cooling air outlets. Also, locate the welder so that the engine exhaust fumes are prop- erly vented to an outside area.

STACKING

Ranger 250 machines cannot be stacked.

ANGLE OF OPERATION

Engines are designed to run in the level condition which is where the optimum performance is achieved. The maximum angle of continuous operation is 15 degrees in any direction. If the engine is to be operat- ed at an angle, provisions must be made for checking and maintaining the oil level at the normal (FULL) oil capacity in the crankcase.

When operating the welder at an angle, the effective fuel capacity will be slightly less than the specified 12 gallons.

HIGH TEMPERATURE OPERATION

At temperatures above 40??C, output de-rating is nec- essary. For maximum output ratings, de-rate the welder output 2Volts for every 10??C above 40??C.

TOWING

The recommended trailer for use with this equipment for road, in-plant and yard towing by a vehicle(1) is Lincoln???s K957-1. If the user adapts a non-Lincoln trailer, he must assume responsibility that the method of attachment and usage does not result in a safety hazard nor damage the welding equipment. Some of the factors to be considered are as follows:

1.Design capacity of trailer vs. weight of Lincoln equipment and likely additional attachments.

2.Proper support of, and attachment to, the base of the welding equipment so there will be no undue stress to the framework.

3.Proper placement of the equipment on the trailer to insure stability side to side and front to back when being moved and when standing by itself while being operated or serviced.

4.Typical conditions of use, i.e., travel speed; rough- ness of surface on which the trailer will be operat- ed; environmental conditions.

5.Conformance with federal, state and local laws.(1)

(1)Consult applicable federal, state and local laws regarding specific requirements for use on public highways.

PRE-OPERATION ENGINE SERVICE

READ the engine operating and maintenance instruc- tions supplied with this machine.

WARNING

???Stop engine and allow to cool before fueling

???Do not smoke when fueling

???Fill fuel tank at a moderate rate and do not overfill

???Wipe up spilled fuel and allow fumes to clear before starting engine

???Keep sparks and flame away from tank

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OIL

The RANGER 250 is shipped with the engine crankcase filled with high quality SAE 10W-30 oil. Check the oil level before starting the engine. If it is not up to the full mark on the dip stick, add oil as required. Check the oil level every four hours of run- ning time during the first 25 running hours. Refer to the engine Operator???s Manual for specific oil recom- mendations and break-in information. The oil change interval is dependent on the quality of the oil and the operating environment. Refer to the Engine Operator???s Manual for the proper service and maintenance inter- vals.

FUEL

USE GASOLINE FUEL ONLY

WARNING

Fill the fuel tank with clean, fresh fuel. The capaci- ty of the fuel tank is 12 gallons (45.4 liters). When the fuel gauge reads empty the tank contains approximately 2 gallons (45.4 liters).of reserve fuel.

NOTE: The fuel tank is mounted below the engine so a fuel shutoff valve is not required.

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ENGINE COOLING SYSTEM

Air to cool the engine is drawn in lower set of louvers on the case back. It is important that the intake air is not restricted. Allow a minimum clearance of 2 feet (0.6m) from the case back to a vertical surface.

BATTERY CONNECTION

CAUTION

Use caution as the electrolyte is a strong acid that can burn skin and damage eyes.

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The RANGER 250 is shipped with the negative bat- tery cable disconnected. Make certain that the RUN- STOP switch is in the STOP position. Remove the two screws from the rear battery tray using a screwdriver or a 3/8" socket. Attach the negative battery cable to the negative battery terminal and tighten using a 1/2" socket or wrench.

NOTE: This machine is furnished with a wet charged battery; if unused for several months, the battery may require a booster charge. Be careful to charge the bat- tery with the correct polarity.

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MUFFLER OUTLET PIPE

Using the clamp provided secure the outlet pipe to the outlet tube with the pipe positioned such that it will direct the exhaust in the desired direction. Tighten using a 9/16" socket or wrench.

SPARK ARRESTER

Some federal, state or local laws may require that gasoline or diesel engines be equipped with exhaust spark arresters when they are operated in certain locations where unarrested sparks may present a fire hazard. The standard muffler included with this welder does not qualify as a spark arrester. When required by local regulations, a suitable spark arrester, such as the S24647 must be installed and properly main- tained.

CAUTION

An incorrect spark arrester may lead to damage to the engine or adversely affect performance.

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HIGH FREQUENCY GENERATORS FOR

TIG APPLICATIONS

The K930-2 TIG Module is suitable for use with the Ranger 250. The Ranger 250 and any high frequency generating equipment must be properly grounded. See the K930-2 Operating Manual for completed instructions on installation, operation, and mainte- nance.

REMOTE CONTROL

The Ranger 250 is equipped with a 6 pin and a 14 pin Amphenol connector. The 6 pin connector is for con- necting the K857 or K857-1 Remote Control (optional) or for TIG welding, the K870 foot Amptrol or the K812 hand Amptrol.

When in the CC-STICK, PIPE, and CV-WIRE modes and when a remote control is connected to the Amphenol, the auto-sensing circuit in the Ranger 250 automatically switches the OUTPUT control from con- trol at the welder to remote control .

The 14 pin connector is used to directly connect a wire feeder or TIG Module (K930-2) control cable. In the CV-WIRE mode, the Ranger 250 auto-sensing cir- cuit automatically makes the Ranger 250 Output Control inactive and the wire feeder voltage control active when the control cable is connected to the 14 pin connector.

NOTE: When a wire feeder with a built in welding volt- age control is connected to the 14 pin connector, do not connect anything to the 6 pin connector.

ELECTRICAL CONNECTIONS

MACHINE GROUNDING

Because this portable engine driven welder

creates its own power, it is not necessary to connect its frame to an earth ground, unless the machine is connected to premises wiring (home, shop, etc.)

To prevent dangerous electric shock, other equipment to which this engine driven welder supplies power must:

1)Be grounded to the frame of the welder using a grounded type plug.

2)Be double insulated.

WARNING

Do not ground the machine to a pipe that carries explosive or combustible material.

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When this welder is mounted on a truck or trailer, its frame must be securely connected to the metal frame of the vehicle. When this engine driven welder is con- nected to premises wiring such as that in a home or shop, its frame must be connected to the system earth ground. See further connection instructions in the sec- tion entitled "Standby Power Connections" as well as the article on grounding in the latest U.S. National Electrical Code and the local code.

In general, if the machine is to be grounded, it should be connected with a #8 or larger copper wire to a solid earth ground such as a metal water pipe going into the ground for at least ten feet and having no insulat- ed joints, or to the metal framework of a building which has been effectively grounded.

The U.S. National Electrical Code lists a number of alternate means of grounding electrical equipment. A machine grounding stud marked with the symbol is provided on the front of the welder.

WELDING TERMINALS

The Ranger 250 is equipped with a toggle switch for selecting "hot" welding terminal when in the "WELD TERMINALS ON" position or "cold" welding terminal when in the "REMOTELY CONTROLLED" position.

WELDING OUTPUT CABLES

With the engine off connect the electrode and work cables to the output studs. The welding process dic- tates the polarity of the electrode cable. These con- nections should be checked periodically and tightened with a 3/4" wrench.

Table A.1 lists recommended cable sizes and lengths for rated current and duty cycle. Length refers to the distance from the welder to the work and back to the welder. Cable diameters are increased for long cable lengths to reduce voltage drops.

TOTAL COMBINED LENGTH OF

ELECTRODE AND WORK CABLES

TABLE A-1

CABLE INSTALLATION

Install the welding cables to your RANGER 250 as fol- lows.

1.The gasoline engine must be OFF to install welding cables.

2.Remove the flanged nuts from the output terminals.

3.Connect the electrode holder and work cables to the weld output terminals. The terminals are identi- fied on the case front.

4.Tighten the flanged nuts securely.

5.Be certain that the metal piece you are welding (the ???work???) is properly connected to the work clamp and cable.

6. Check and tighten the connections periodically.

???Loose connections will cause the output terminals to overheat. The terminals may eventually melt.

CAUTION

???Do not cross the welding cables at the output terminal connection. Keep the cables isolated and separate from one another.

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AUXILIARY POWER RECEPTACLES

The auxiliary power of the RANGER 250 consists of two 20 Amp-120 VAC (5-20R) duplex receptacles and one 50 Amp 120/240 VAC (14-50R) receptacle. The 240 VAC receptacle can be split for single phase 120 VAC operation.

The auxiliary power capacity is 9,000 Watts Peak, 8500 Watts Continuous of 60 Hz, single phase power. The auxiliary power capacity rating in watts is equiva- lent to volt-amperes at unity power factor. The max permissible current of the 240 VAC output is 35 Amps. The 240 VAC output can be split to provide two sepa- rate 120 VAC outputs with a max permissible current of 35 Amps per output to two separate 120 VAC branch circuits (these circuits cannot be paralleled). Output voltage is within ?? 10% at all loads up to rated capacity.

The 120 V auxiliary power receptacles should only be used with three wire grounded type plugs or approved double insulated tools with two wire plugs. The current rating of any plug used with the system must be at least equal to the current capacity of the associated receptacle.

NOTE: The 240 V receptacle has two 120 V circuits, but are of opposite polarities and cannot be paralleled.

STANDBY POWER CONNECTIONS

The RANGER 250 is suitable for temporary, standby or emergency power using the engine manufacturer???s recommended maintenance schedule.

The RANGER 250 can be permanently installed as a standby power unit for 240 VAC, 3 wire, single phase, 35 amp service. Connections must be made by a licensed electrician who can determine how the 120/240 VAC power can be adapted to the particular installation and comply with all applicable electrical codes.

1.Install the double-pole, double-throw switch between the power company meter and the premis- es disconnect. Switch rating must be the same or greater than the customer???s premises disconnect and service over current protection.

2.Take necessary steps to assure load is limited to the capacity of the RANGER 250 by installing a 40 amp, 240 VAC double pole circuit breaker. Maximum rated load for each leg of the 240 VAC auxiliary is 35 amperes. Loading above the rated output will reduce output voltage below the allow- able - 10% of rated voltage which may damage appliances or other motor-driven equipment and may result in overheating of the RANGER 250 engine and/or alternator windings.

3.Install a 50 amp, 120/240 VAC plug (NEMA Type 14-50) to the double-pole circuit breaker using No. 6, 4 conductor cable of the desired length. (The 50 amp, 120/240 VAC plug is available in the optional K802R plug kit or as part number T12153-9.)

4.Plug this cable into the 50 Amp, 120/240 Volt receptacle on the RANGER 250 case front.

CONNECTION OF LINCOLN ELEC-

TRIC WIRE FEEDERS

Connection of LN-7 or LN-8 to the Ranger 250

1.Shut the welder off.

2.Connect the LN-7 or LN-8 per instructions on the appropriate connection diagram in Section F

3.Set the "WIRE FEEDER VOLTMETER" switch to either "+" or "-" as required by the electrode being used.

4.Set the "MODE" switch to the "CV WIRE " posi- tion.

5.Set the "ARC CONTROL" knob to "0" initially and adjust to suit.

6 Set the "WELD TERMINALS" switch to the "REMOTELY CONTROLLED" position.

7. Set the "IDLE" switch to the "HIGH" position.

Connection of an LN-23P Wire Feeder to the Ranger 250

1.Shut the welder off.

2.Connect the LN-23P as per instructions on the appropriate connection diagram in Section F. (NOTE): When connecting an LN-23P to the Ranger 250, a K350-1 adapter kit must be used.

3.Set the "VOLTMETER" switch to "-".

4.Set the "MODE" switch to "CV WIRE" position.

5.Set the "WELD TERMINALS" switch to

"REMOTELY CONTROLLED".

6.Set the "ARC CONTROL" knob to "0" initially and adjust to suit.

7.Set the "IDLE" switch to the "AUTO" position. When not welding, the Ranger 250 engine will be at the low idle speed. If you are using an LN-23P with the K350-1 adapter kit, the electrode is not energized until the gun trigger is closed. When the gun trigger is closed, the current sensing cir- cuit will cause the Ranger 250 engine to go to the high idle speed, the wire will begin to feed and the welding process can be started. When welding is stopped, the engine will revert to low idle speed after approximately 12 seconds unless welding is resumed.

Connection of the LN-25 to the Ranger 250

The LN-25 with or without an external contactor may be used with the Ranger 250. See the appropriate connection diagram in Section F.

Note: The LN-25 (K431) Remote Control Module and (K432) Remote Cable are not recommended for use with the Ranger 250.

1.Shut the welder off.

2.For electrode Positive, connect the electrode cable from the LN-25 to the "+" terminal of the welder and work cable to the "-" terminal of the welder. For electrode Negative, connect the elec- trode cable from the LN-25 to the "-" terminal of the welder and work cable to the "+" terminal of the welder.

3.Attach the single lead from the front of the LN-25 to work using the spring clip at the end of the lead. This is a control lead to supply current to the wire feeder motor; it does not carry welding current.

4.Set the MODE switch to the "CV-WIRE " position.

5.Set the "WELD TERMINALS" switch to "WELD

TERMINALS ON"

6.Set the "ARC CONTROL" knob to "0" initially and adjust to suit.

7.Set the "IDLE" switch to the "AUTO" position. When not welding, the Ranger 250 engine will be at the low idle speed. If you are using an LN-25 with an internal contactor, the electrode is not energized until the gun trigger is closed.

8.When the gun trigger is closed, the current sens- ing circuit will cause the Ranger 250 engine to go to the high idle speed, the wire will begin to feed and the welding process started. When welding is stopped, the engine will revert to low idle speed after approximately 12 seconds unless welding is resumed.

Connection of LN-742, Spool Gun, and Cobramatic to Ranger 250

1.Shut the welder off.

2.Connect per instructions on the appropriate con- nection diagram in Section F.

SAFETY PRECAUTIONS

Read and understand this entire section before operating your Ranger 250.

Do not attempt to use this equipment until you have thoroughly read all operating and mainte- nance manuals supplied with your machine. They include important safety precautions, detailed engine starting, operating and maintenance instructions and parts lists.

ELECTRIC SHOCK can kill.

???Do not touch electrically live parts such as output terminals or internal wiring.

???Insulate yourself from the work and ground.

???Always wear dry insulating gloves.

------------------------------------------------------------------------

ENGINE EXHAUST can kill.

???Use in open, well ventilated areas or vent exhaust outside

???Do not stack anything near the engine.

------------------------------------------------------------------------

MOVING PARTS can injure.

???Do not operate with doors open or guards off.

???Stop engine before servicing.

???Keep away from moving parts

------------------------------------------------------------------------

???Only qualified personnel should operate this equipment.

ADDITIONAL SAFETY PRECAUTIONS

Always operate the welder with the hinged door closed and the side panels in place as these pro- vide maximum protection from moving parts and insure proper cooling air flow.

GENERAL DESCRIPTION

The Ranger 250 is a gasoline engine powered DC multi-process welding power source and 120 / 240 volt AC power generator. The engine drives a genera- tor that supplies three phase power for the DC weld- ing circuit and single phase power for the AC auxiliary outlets. The DC welding control system uses state of the art Chopper Technology (CT tm) for superior weld- ing performance. The Ranger 250 is not recom- mended for pipe thawing.

DESIGN FEATURES

ENGINE OPERATION

Before Starting the Engine:

1.Be sure the machine is on a level surface.

2.Open top engine door and remove the engine oil dipstick and wipe it with a clean cloth. Reinsert the dipstick and check the level on the dipstick.

3.Add oil (if necessary) to bring the level up to the full mark. Do not overfill. Close engine door.

4.See Engine Owner???s Manual for specific oil recom- mendations.

ADD FUEL

WARNING

GASOLINE can cause fire or explosion.

??? Stop engine when fueling.

???Do not smoke when fueling.

???Do not overfill tank.

???Avoid contact with skin or breathing of vapor.

???Keep sparks and flame away from tank.

------------------------------------------------------------------------

1. Remove the fuel tank cap.

2.Fill the tank approximately 4 inches (100mm) from the top of the filler neck to allow for fuel expansion (observe the fuel gauge while filling). DO NOT FILL

THE TANK TO THE POINT OF OVERFLOW.

3.Replace the fuel cap and tighten securely.

4.See Engine Owner???s Manual for specific fuel rec- ommendations.

1

2

3

4

WELDING CONTROLS:

1. OUTPUT CONTROL: The CONTROL dial provides continuous control of the welding current or welding voltage depending on the selected welding mode. This control is not active in the CC-STICK, PIPE, and CV-WIRE modes when a remote control or wire feeder with remote control is connected to either the 6 pin or 14 pin Amphenol.

2. WELD MODE SELECTOR SWITCH:

(Provides four selectable welding modes)

CV-WIRE

PIPE

CC-STICK

TOUCH START TIG

15 14

13

12

11

10

9

8

7

6

5

CC-STICK/PIPE modes: In these modes, the ARC CONTROL knob sets the short circuit current during stick welding (arc-force). Increasing the number from - 10 to +10 increases the short circuit current and pre- vents sticking of the electrode to the plate while weld- ing. This can also increase spatter. It is recommended that the ARC CONTROL be set to the minimum num- ber without electrode sticking. Start with a setting at 0.

CV-WIRE mode: In this mode, turning the ARC CON- TROL clockwise from ???10 (soft) to +10 (crisp) changes the arc from soft and washed-in to crisp and narrow. It acts as an inductance control. The proper setting depends on the procedure and operator preference. Start with a setting at 0.

3. ARC CONTROL :

The ARC CONTROL WIRE/STICK dial is active in the WIRE, STICK and PIPE modes, and has different functions in these modes. This control is not active in the TIG mode. DC PIPE mode for machines below code 10900.

4. WELD OUTPUT TERMINALS WITH

FLANGE NUT:

Provides a connection point for the electrode and work cables.

5. GROUND STUD: (graphic)

Provides a connection point for connecting the machine case to earth ground for the safest grounding procedure.

6. 14-PIN AMPHENOL:

For attaching wire feeder control cables to the Ranger 250. Includes contactor closure circuit, auto-sensing remote control circuit, and 120V and 42V power. The remote control circuit operates the same as the 6 Pin Amphenol.

7. 6-PIN AMPHENOL:

For attaching optional remote control equipment. When in the CC-STICK, PIPE, and CV-WIRE modes and when a remote control is connected to the Amphenol, the auto-sensing circuit in the Ranger 250 automatically switches the OUTPUT control from con- trol at the welder to remote control .

When using the TOUCH START TIG mode with a TIG Module connected to the Ranger 250, the OUTPUT control on the front of the Ranger 250 is used to set the maximum current range of the CURRENT CON- TROL on the TIG Module.

8. WELD TERMINALS CONTROL SWITCH:

In the WELD TERMINALS ON position, the output is electrically hot all the time. In the REMOTELY CON- TROLLED position, the output is controlled by a wire feeder or amptrol device, and is electrically off until a remote switch is depressed.

9. WIRE FEEDER VOLTMETER SWITCH:

Matches the polarity of the wire feeder voltmeter to the polarity of the electrode.

ENGINE CONTROLS:

10. RUN/STOP SWITCH - RUN position ener- gizes the engine prior to starting. STOP position stops the engine. The oil pressure interlock switch prevents battery drain if the switch is left in the RUN position and the engine is not operating.

11. CHOKE - When pulled out, it closes the choke valve on the engine carburetor for quick starting.

12. START PUSH BUTTON - Energizes the starter motor to crank the engine.

13. IDLER SWITCH- Has two positions as follows:

1)In the HIGH position, the engine runs at the high idle speed controlled by the engine governor.

2)In the AUTO position, the idler operates as follows:

???When switched from HIGH to AUTO or after start- ing the engine, the engine will operate at full speed for approximately 12 seconds and then go to low idle speed.

???When the electrode touches the work or power is drawn for lights or tools (approximately 100 Watts minimum), the engine accelerates and operates at full speed.

???When welding ceases or the AC power load is turned off, a fixed time delay of approximately 12 seconds starts. If the welding or AC power load is not restarted before the end of the time delay, the idler reduces the engine speed to low idle speed.

???The engine will automatically return to high idle speed when there is welding load or AC power load reapplied.

14. ENGINE ALTERNATOR TROUBLE LIGHT-The engine alternator light is off when battery charging system is functioning normally. If light turns on, the alternator or the voltage regulator may not be operating correctly. The light may also come on due to the battery not holding a charge. It is normal for the light to come on during shut down of the engine. The light will remain lit with the meters for a short period of time after the engine has shut down.

15. ENGINE HOUR METER ??? Displays the total time that the engine has been running. This meter is useful for scheduling prescribed maintenance.

STARTING AND STOPPING

THE ENGINE

1.Remove all plugs connected to the AC power receptacles.

2.Set IDLER switch to AUTO.

3.Set the RUN/STOP switch to RUN.

4.Pull the choke to the full out position.

5.Press and hold the engine START button until the engine starts.

6.Release the engine START button when the engine starts.

7.Push the choke back in.

8.The engine will run at high idle speed for approxi- mately 12 seconds and then go to low idle speed. Allow the engine to warm up at low idle for several minutes before applying a load and/or switching to high idle. Allow a longer warm up time in cold weather.

CAUTION

Operating the starter motor for more than 5 sec- onds can damage the motor. If the engine fails to start, release the switch and wait 10 seconds before operation the starter again. Do NOT push the START button while the engine is running because this can damage the ring gear and/or the starter motor.

NOTE: When starting a Ranger 250 for the first time, or after an extended period of time of not operating, it will take longer than normal because the fuel pump has to fill the fuel line and carburetor.

STOPPING

Remove all welding and auxiliary power loads and allow the engine to run at low idle speed for a few minutes to cool the engine.

Stop the engine by placing the RUN-STOP in the STOP position.

NOTE: A fuel shut off valve is not required on the Ranger 250 because the fuel tank is mounted below the engine.

WELDER OPERATION

DC Stick Welding

The Ranger 250 can be used with a broad range of DC stick electrodes.

The MODE switch provides two stick welding settings as follows:

Constant Current (CC-STICK) Welding

The CC-STICK position of the MODE switch is designed for horizontal and vertical-up welding with all types of electrodes, especially low hydrogen. The out- put CONTROL dial adjusts the full output range for stick welding.

The ARC CONTROL knob sets the short circuit cur- rent during stick welding (arc-force). Increasing the number from -10 to +10 increases the short circuit cur- rent and prevents sticking of the electrode to the plate while welding. This can also increase spatter. It is rec- ommended that the ARC CONTROL be set to the minimum number without electrode sticking. Start with the dial set at 0.

PIPE Welding

This slope controlled setting is intended for "out-of- position" and "down hill" pipe welding where the oper- ator would like to control the current level by changing the arc length. The output CONTROL dial adjusts the full output range for pipe welding. The ARC CON- TROL knob sets the short circuit current during stick welding (arc-force). Increasing the number from -10 to +10 increases the short circuit current and prevents sticking of the electrode to the plate while welding. This can also increase spatter. It is recommended that the ARC CONTROL be set to the minimum number without electrode sticking. Start with the dial set at 0.

TIG WELDING

The TOUCH START TIG setting of the MODE switch is for DC TIG (Tungsten Inert Gas) welding. To initiate a weld, the CONTROL dial is first set to the desired current and the tungsten is touched to the work. During the time the tungsten is touching the work there is very little voltage or current and, in general, no tungsten contamination. Then, the tungsten is gently lifted off the work in a rocking motion, which establishes the arc.

The ARC CONTROL is not active in the TIG mode. To STOP a weld, simply pull the TIG torch away from the work. When the arc voltage reaches approximately 30 Volts the arc will go out and the machine will reset the cur- rent to the Touch Start level. To reinitiate the arc, retouch the tungsten to the work and lift. Alternatively, the weld can be stopped by releasing the Amptrol or arc start switch.

The Ranger 250 can be used in a wide variety of DC TIG welding applications. In general the ???Touch Start??? feature allows contamination free starting without the use of a Hi- frequency unit. If desired, the K930-2 TIG Module can be used with the Ranger 250. The settings are for reference.

Ranger 250 settings when using the K930-2 TIG Module with an Amptrol or Arc Start Switch:

???Set the MODE Switch to the TOUCH START TIG setting.

???Set the "IDLER" Switch to the "AUTO" position.

???Set the "WELDING TERMINALS" switch to the "REMOTELY CONTROLLED" position. This will keep the "Solid State" contactor open and provide a "cold" electrode until the Amptrol or Arc Start Switch is pressed.

When using the TIG Module, the OUTPUT control on the Ranger 250 is used to set the maximum range of the CURRENT CONTROL on the TIG Module or an Amptrol if connected to the TIG Module.

WIRE WELDING-CV

Connect a wire feeder to the Ranger 250 according to the instructions in INSTALLATION INSTRUCTIONS Section.

The Ranger 250 in the CV-WIRE mode, permits it to be used with a broad range of flux cored wire (Innershield and Outershield) electrodes and solid wires for MIG welding (gas metal arc welding). Welding can be finely tuned using the ARC CON- TROL. Turning the ARC CONTROL clockwise from ???10 (soft) to +10 (crisp) changes the arc from soft and washed-in to crisp and narrow. It acts as an induc- tance control. The proper setting depends on the pro- cedure and operator preference. Start with the dial set at 0.

Listed below are some wires suitable for use on this machine:

???Innershield - NR-311, NS-3M, NR-207, NR-203 Ni 1%, NR-204-H.

???Outershield - 0S-70, 0S-71M.

???Solid wires for MIG welding - .035 (0.9 mm), and

.045 (1.1 mm), L-50 and L-56, .035 (0.9 mm) and

.045 (1.1 mm) Blue Max MIG 308 LS.

Contact your local authorized Lincoln Electric Distributor or the Lincoln Electric Company for specific wires used on certain applications with this machine.

ARC GOUGING

The Ranger 250 can be used for limited arc gouging. For optimal performance, set the MODE switch to CC- STICK and the ARC CONTROL to +10.

Set the CONTROL knob to adjust output current to the desired level for the gouging electrode being used according to the ratings in the following table.

AUXILIARY POWER:

Start the engine and set the IDLER control switch to the desired operating mode. Full power is available regardless of the welding control settings providing no welding current is being drawn.

The auxiliary power of the RANGER 250 consists of two 20 Amp-120 VAC (5-20R) duplex receptacles and one 50 Amp 120/240 VAC (14-50R) receptacle. The 240 VAC receptacle can be split for single phase 120 VAC operation.

The auxiliary power capacity is 9,000 Watts Peak, 8500 Watts Continuous of 60 Hz, single phase power. The auxiliary power capacity rating in watts is equiva- lent to volt-amperes at unity power factor. The max permissible current of the 240 VAC output is 35 Amps.

The 240 VAC output can be split to provide two sepa- rate 120 VAC outputs with a max permissible current of 35 Amps per output to two separate 120 VAC branch circuits (these circuits cannot be paralleled). Output voltage is within ?? 10% at all loads up to rated capacity.

The 120 V auxiliary power receptacles should only be used with three wire grounded type plugs or approved double insulated tools with two wire plugs. The current rating of any plug used with the system must be at least equal to the current capacity of the associated receptacle.

NOTE: The 240 V receptacle has two circuits, each of which measure 120 V to neutral but are of opposite polarities and cannot be paralleled.

Simultaneous Welding and Auxiliary Power Loads

The above auxiliary power ratings are with no welding load. Simultaneous welding and power loads are specified in the following table. The permissible cur- rents shown assume that current is being drawn from either the 120 VAC or 240 VAC supply (not both at the same time).

RECOMMENDED OPTIONAL

EQUIPMENT

K957-1 HEAVY DUTY, TWO WHEEL TRAILER FOR SMALL WELDERS - For road, off-road and in-plant and yard towing. (For highway use, consult applicable federal, state and local laws regarding requirements for brakes, lights, fenders, etc.). Order:

K957-1 Trailer

K958-1 Ball Hitch

K958-2 Lunette Eye Hitch

K959-2 Fender & Light Kit

K965-1 Cable Storage Rack

K1737-1 FOUR WHEEL ALL-TERRAIN UNDER- CARRIAGE - For moving by hand at construction sites. Heavy duty puncture resistant pneumatic tires.

K1770-1 UNDERCARRIAGE (FACTORY)

For moving by hand on a smooth surface. Heavy duty puncture resistant pneumatic tires and front caster. One or two gas cylinders can be mounted on the rear of the undercarriage with the installation of K1745-1 Cylinder Holder(s).

K1739-1 CABLE CARRIER KIT - For use on K1737-1 and K1770-1 Undercarriages.

K1745-1 SINGLE GAS CYLINDER HOLDER - For use on K1770-1 Undercarriage. One or two may be installed on an undercarriage.

K1788-1 ROLL CAGE - Gives added damage protection.

K886-2 CANVAS COVER - Protects machine when not in use.

K1898-1 SPARK ARRESTER - Mounts inside exhaust pipe.

K704 ACCESSORY KIT - 400 Amp Stick welding Accessory Kit (Includes Headshield, electrode cable holder, work cable and work clamp.

K857 25 ft (7.5m) or K857-1 100 ft. (30.4m) REMOTE CON- TROL - Portable control provides same dial range as the output control on the welder. Has a convenient 6 pin plug for easy connection to the welder.

K1690-1 GFCI RECEPTACLE KIT - Includes one UL approved 120V ground fault circuit interrupter duplex type receptacle with cover and installation instruc- tions. Replaces the factory installed 120V duplex

receptacle. Each receptacle of the GFCI Duplex is rated at 20 Amps, the maximum total current from the

GFCI Duplex is limited to the 20 Amps. Two kits are required.

K802-N POWER PLUG KIT

Provides four 120 volt plugs rated at 20 amps each and one dual voltage, full KVA plug rated at 120/240 volts, 50 amps.

K802-R POWER PLUG KIT

Provides four 120 volt plugs rated at 15 amps each and one dual voltage, full KVA plug rated at 120/240 volts, 50 amps.

T12153-9 50 AMP, 120/240V POWER PLUG

K1816-1 FULL KVA ADAPTER KIT

Plugs into the 120/240V NEMA 14-50R receptacle on the case front (which accepts 4-prong plugs) and con- verts it to a NEMA 6-50R receptacle, (which accepts 3-prong plugs.)

TIG Welding

K1783-9 TIG Torch PTA-26V (25ft.)

K963-2 Hand Amptrol

K870 Foot Amptrol

S19257-2 Power Cable Adapter

KP506 Magnum Hook-Up Kit

KP509 Magnum Parts Kit

Spool Gun

K1692-2 Prince XL Spool Gun (25ft.)

SAFETY PRECAUTIONS

WARNING

???Have qualified personnel do all maintenance and troubleshooting work.

???Turn the engine off before working inside the machine or servicing the engine.

???Remove guards only when necessary to perform maintenance and replace them when the maintenance requiring their removal is complete. If guards are missing from the machine, obtain replacements from a Lincoln Distributor. (See Operating Manual Parts List.)

Read the Safety Precautions in the front of this manual and in the Engine Owner???s Manual before working on this machine.

Keep all equipment safety guards, covers, and devices in position and in good repair. Keep hands, hair, clothing, and tools away from the gears, fans, and all other moving parts when starting, operating, or repairing the equipment.

Routine Maintenance

At the end of each day???s use, refill the fuel tank to minimize moisture condensation in the tank. Running out of fuel tends to draw dirt into the fuel system. Also, check the crankcase oil level and add oil if indicated.

KOHLER ENGINE

(1)Service more frequently when used in dusty areas and/or at high ambient temperatures.

ONAN P220 OHV

(1)Service more frequently when used in dusty areas and/or at high ambient temperatures.

ENGINE OIL CHANGE

Drain the oil while the engine is warm to assure rapid and complete draining.

???Remove the oil filler cap and dipstick. Remove the yellow cap from the oil drain valve and attach the flexible drain tube supplied with the machine. Push in and twist the drain valve counterclockwise. Pull the valve out and drain the oil into a suitable contain- er.

???Close the drain valve by pushing in and twisting clockwise. Replace the yellow cap.

???Refill to the upper limit mark on the dipstick with the recommended oil. Tighten the oil filler cap securely.

ENGINE OIL REFILL CAPACITIES

Without oil filter replacement:

???1.7 US qt. (1.4 Imp qt., 1.6 liter)-Kohler

???1.5 US qt. (1.2 Imp qt., 1.4 liter)-Onan P220 OHV

With oil filter replacement:

???2.0 US qt. (1.7 Imp qt., 1.9 liter)-Kohler

???1.65 US qt. (1.4 Imp qt., 1.6 liter)-Onan P220 OHV

Use 4-stroke motor oil that meets or exceeds the requirements for API service classification SG or SH. Always check the API SERVICE label on the oil con- tainer to be sure it includes the letters SG or SH.

SAE 10W-30 is recommended for general, all-temper- ature use, -5 F to 104 F (-20 C to 40 C). For the Onan engine, it is recommended that SAE 30 oil be used above 82 F (27 C).

See Engine Owner???s Manual for more specific infor- mation on oil viscosity recommendations.

Wash your hands with soap and water after handling used oil.

Please dispose of used motor oil in a manner that is compatible with the environment. We suggest you take it in a sealed container to your local service sta- tion or recycling center for reclamation. Do not throw it in the trash, pour it on the ground or down a drain.

OIL FILTER CHANGE

1.Drain the engine oil.

2.Remove the oil filter, and drain the oil into a suitable container. Discard the used oil filter.

3.Clean the filter mounting base, and coat the gasket of the new oil filter with clean engine oil.

4.Screw on the new oil filter by hand, until the gasket contacts the filter mounting base, then use an oil fil- ter socket tool to tighten the filter an additional 1/2 to 7/8 turn.

5.Refill the crankcase with the specified amount of the recommended oil. Reinstall the oil filler cap.

6.Start the engine and check for oil filter leaks.

7.Stop the engine, and check the oil level. If neces- sary, add oil to the upper limit mark on the dipstick.

AIR CLEANER SERVICE

A dirty air cleaner will restrict air flow to the carbure- tor. To prevent carburetor malfunction, service the air cleaner regularly. Service more frequently when operating the engine in extremely dusty areas.

WARNING

???Never use gasoline or low flash point solvents for cleaning the air cleaner element. A fire or explosion could result.

CAUTION

???Never run the engine without the air cleaner. Rapid engine wear will result from contaminants, such as dust and dirt being drawn into the engine.

-----------------------------------------------------------------------

AIR PRE-CLEANER SERVICE

1.Loosen the cover retaining knob and remove the cover.

2.Remove the pre-cleaner from the paper element.

3.Wash the pre-cleaner in warm water with detergent. Rinse the pre-cleaner thoroughly until all traces of detergent are eliminated. Squeeze out excess water (do not wring). Allow the pre-cleaner to air dry.

4.Saturate the pre-cleaner with new engine oil. Squeeze out all excess oil.

5.Reinstall the pre-cleaner over the paper element.

6.Reinstall the air cleaner cover. Secure cover with the cover retaining knob.

AIR FILTER PAPER ELEMENT

1.Loosen the cover retaining knob and remove the cover.

2.Remove the pre-cleaner from the paper element.

3.Remove the element cover nut, element cover, and paper element.

4.Do not wash the paper element or use pressurized air, as this will damage the element. Replace a dirty, bent, or damaged element with a new ele- ment. Handle new elements carefully; do not use if the sealing surfaces are bent or damaged.

5.When servicing the air cleaner, check the air cleaner base. Make sure it is secured and not bent or dam- aged. Also check the element cover for damaged or improper fit. Replace all damaged air cleaner com- ponents.

NOTE: Before air cleaner is reassembled make sure rubber seal is in position around stud. Inspect, making sure it is not damaged and seals with the element cover.

6.Reinstall the paper element, pre-cleaner, element cover, element cover nut, and air cleaner cover. Secure cover with the cover retaining knob.

SPARK PLUG

To ensure proper engine operation, the spark plug must be properly gapped and free of deposits.

WARNING

NOTE: Before removing spark plug, the muffler becomes very hot during operation and remains hot for a while after stopping the engine. Be care- ful not to touch the muffler while it is hot.

------------------------------------------------------------------------

SPARK PLUG SERVICE

To ensure proper engine operation, the spark plug must be properly gapped and free of deposits.

1.Remove the spark plug cap.

2.Clean any dirt from around the spark plug base.

3.Use a plug wrench to remove the spark plug.

4.Visually inspect the spark plug. Discard them if the insulator is cracked or chipped. Clean the spark plug with a wire brush if it is to be reused.

5.Measure the plug gap with a feeler gauge. Correct as necessary by bending the side electrode.

6.Check that the spark plug washer is in good condi- tion and thread the spark plug in by hand to prevent cross-threading.

7.After the spark plug is seated, tighten with a spark plug wrench to compress the washer. (See proper spark plug torque which is specified below).

Spark Plug Gap: .030 in. (0.76 mm)-Kohler Engine

.025 in. (0.64 mm)-Onan Engine???s

Spark Plug Torque: 20 ft. Lb. (27 N-m)-Kohler Engine 11 ft. Lb. (14 N-m)-Onan Engine???s

CAUTION

The spark plug must be securely tightened. An improperly tightened spark plug can become very hot and may cause engine damage.

Use only the recommended spark plug or equiva- lent. A spark plug which has an improper heat range may cause engine damage.

------------------------------------------------------------------------

FUEL FILTER

1.Check the fuel filter for water accumulation or sedi- ment.

2.Replace the fuel filter if it is found with excessive water accumulation or sediment.

ENGINE ADJUSTMENT

OVERSPEED IS HAZARDOUS

The maximum allowable high idle speed for this machine is 3750 RPM, no load. Do NOT tamper with governor components or setting or make any other adjustments to increase the maximum speed. Severe personal injury and damage to the machine can result if operated at speeds above maximum.

Adjustments to the engine are to be made only by a Lincoln Service Center or an authorized Field Service Shop.

BATTERY MAINTENANCE

To access the battery, Remove the 2 screws from the rear battery tray using a screwdriver or a 3/8" socket. Slide the battery tray out only far enough to access the battery terminals.

WARNING

GASES FROM BATTERY can explode.

??? Keep sparks, flame and cigarettes away from battery.

To prevent EXPLOSION when:

???INSTALLING A NEW BATTERY ??? disconnect negative cable from old battery first and con- nect to new battery last.

???CONNECTING A BATTERY CHARGER ??? remove battery from welder by disconnecting negative cable first, then positive cable and battery clamp. When reinstalling, connect negative cable last. Keep well ventilated.

???USING A BOOSTER ??? connect positive lead to battery first then connect negative lead to neg- ative battery lead at engine foot.

BATTERY ACID can burn eyes and skin.

??? Wear gloves and eye protection and be careful when working near battery.

??? Follow instructions printed on battery.

CLEANING THE BATTERY

Keep the battery clean by wiping it with a damp cloth when dirty. If the terminals appear corroded, discon- nect the battery cables and wash the terminals with an ammonia solution or a solution of 1/4 pound (0.12 kg) of baking soda and 1 quart (0.9461liter) of water. Be sure the battery vent plugs (if equipped) are tight so that none of the solution enters the cells.

After cleaning, flush the outside of the battery, the bat- tery compartment, and surrounding areas with clear water. Coat the battery terminals lightly with petroleum jelly or a non-conductive grease to retard corrosion.

Keep the battery clean and dry. Moisture accumula- tion on the battery can lead to more rapid discharge and early battery failure.

CHECKING THE ELECTROLYTE LEVEL

If battery cells are low, fill them to the neck of the filler hole with distilled water and recharge. If one cell is low, check for leaks.

CHARGING THE BATTERY

When you charge, jump, replace, or otherwise con- nect battery cables to the battery, be sure the polarity is correct. Improper polarity can damage the charging circuit. The RANGER 250 positive (+) battery terminal has a red terminal cover.

If you need to charge the battery with an external charger, disconnect the negative cable first, then the positive cable before you attach the charger leads. After the battery is charged, reconnect the positive battery cable first and the negative cable last. Failure to do so can result in damage to the internal charger components.

Follow the instructions of the battery charger manu- facturer for proper charger settings and charging time.

SERVICING OPTIONAL SPARK

ARRESTER

Clean every 100 hours.

MUFFLER MAY BE HOT

WARNING

???ALLOW ENGINE TO COOL BEFORE INSTALLING

THE SPARK ARRESTER!

???DO NOT OPERATE ENGINE WHILE INSTALLING

THE SPARK ARRESTER!

------------------------------------------------------------------------------------------

This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three-step procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).

Look under the column labeled ???PROBLEM (SYMP- TOMS)???. This column describes possible symptoms that the machine may exhibit. Find the listing that best describes the symptom that the machine is exhibiting.

Step 2. POSSIBLE CAUSE.

The second column labeled ???POSSIBLE CAUSE??? lists the obvious external possibilities that may contribute to the machine symptom.

Step 3. RECOMMENDED COURSE OF ACTION

This column provides a course of action for the Possible Cause, generally it states to contact your local Lincoln Authorized Field Service Facility.

If you do not understand or are unable to perform the Recommended Course of Action safely, contact your local Lincoln Authorized Field Service Facility.

CAUTION

If all recommended possible areas of misadjustment have been checked and the problem persists,

Contact your local Lincoln Authorized Field Service Facility.

If all recommended possible areas of misadjustment have been checked and the problem persists,

Contact your local Lincoln Authorized Field Service Facility.

The welding arc is ???cold.??? The welding arc is not stable or is not satisfactory. the engine runs nor- mally. The auxiliary power is nor- mal.

1.Make sure the MODE selector switch is in the correct position for the process being used. (For example, CV-WIRE, PIPE, CC- STICK.)

2.Make sure the electrode (wire, gas, voltage, current etc.) is cor- rect for the process being used.

3.Check for loose or faulty con- nections at the weld output ter- minals and welding cable con- nections.

4.The welding cables may be too long or coiled, causing an exces- sive voltage drop.

If all recommended possible areas of misadjustment have been checked and the problem persists,

Contact your local Lincoln

Authorized Field Service Facility.

ENGINE WELDERS /LN-8 CONNECTION DIAGRAM

WARNING

6-F

ELECTRIC SHOCK can kill

Do not operate with panels open.

Disconnect NEGATIVE (-) Battery lead

before servicing.

Do not touch electrically live parts.

MOVING PARTS can injure

Keep guards in place.

Keep away from moving parts. Only qualified personnel should install,use or service this equipment.

250 RANGER

TO WORK

ELECTRODE CABLE

TO WIRE FEED UNIT

CAUTION:

ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE

AN INCREASE IN THE AC WIRE FEEDER VOLTAGE, WHICH CAN DAMAGE THE CONTROL CIRCUIT. THE ENGINE GOVERNOR SETTING IS PRE-SET

AT THE FACTORY ??? DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN THE ENGINE WELDER OPERATING MANUAL.

N.A. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE

APPLICATIONS. SEE OPERATING MANUAL.

N.B. CONNECT WELDING CABLES TO OUTPUT STUDS FOR DESIRED POLARITY. POSITION THE WIRE FEEDER VOLTMETER SWITCH TO

MATCH THE POLARITY OF THE ELECTRODE CABLE.

N.C. PLACE IDLER SWITCH IN ???HIGH??? POSITION.

4-14-2000

S24787-6

DIAGRAMS

6-F